Apparatus and method for loading articles into a packing case

ABSTRACT

An apparatus and method for loading articles into a packing case are provided. The apparatus is a drop packer that utilizes finger guides to guide articles into upward facing openings in packing cases. The finger guides are arranged in sets, and sets of finger guides are arranged in adjacent rows. Each set of finger guides has one generally vertical stationary guide and one movable guide that can be moved into an open or closed position. This configuration of finger guides allows the drop packer to be used to load articles into packing cases that are partially compressed without the need to expand the packing cases before loading.

CROSS REFERENCES

This application claims the benefit of U.S. Provisional Application No. 62/205,273, filed on Aug. 14, 2015, which application is incorporated herein by reference.

BACKGROUND OF THE INVENTION

I. Field of the Invention

The present invention relates to an apparatus for loading articles into a packing case.

II. Description of Related Art

Case or carton packing machines for loading articles into packing cases or cartons are available in many different configurations for a variety of applications. Case or carton packers are typically used to pack articles such as glass or plastic bottles, cans, or jars into cases or cartons for transportation and handling and are capable of packing high volumes of articles. One common type of case or carton packer is a “drop packer” type of loader. With this type of loader, a group of articles is conveyed onto a grid structure and then released to drop down into a packing case or carton below. A structure supporting the packing case or carton may optionally be raised before the articles are dropped into the case to minimize the height of the drop.

Cases or cartons loaded using a drop packer have upward facing openings into which the articles drop. In some drop packers, structures such as finger guides may be used to guide articles downward into the openings in the packing case or carton. In order for the loading process to function properly, the packing cases or cartons need to be fully expanded to maximum size so that the size of the openings in the cases are maximized in order to receive articles being loaded therein. Otherwise, the openings may not align with the finger guides and may also be too small to receive articles therein.

For the aforementioned reasons, currently utilized configurations of drop packers will not function properly in loading beverage bottles into packing cases or cartons that are partially compressed. For instance, carriers for holding beverage bottles may be made of paperboard or similar material that may be partially compressed after manufacturing. To utilize currently designed drop packers, such cases may need to be physically expanded to maximum size before loading. This additional step may significantly slow the loading process and may add additional costs to the process.

Accordingly, it would be advantageous to provide an apparatus and method for loading articles into partially compressed packing cases or cartons.

BRIEF SUMMARY OF THE INVENTION

In one aspect, an apparatus for loading articles into packing cases or cartons is provided. The apparatus drops articles downward from a grid unit into packing cases or cartons below. The apparatus utilizes finger guides to guide each article downward into an upward facing opening in a packing case or carton. Each article drops through a chute defined by a set of finger guides. Each set of finger guides comprises a stationary finger guide configured in a generally vertical position and a movable finger guide that can be moved into an open position or into a closed position. When in the open position, an article is allowed to drop through the chute. When in the closed position, the movable finger guide is positioned at an acute angle to the stationary guide.

The grid unit comprises a plurality of finger guides arranged in sets, wherein sets of finger guides are arranged in adjacent rows. In this embodiment, each generally vertical stationary finger guide in a row of finger guide sets is positioned adjacent to another generally vertical stationary finger guide located in an adjacent row. This configuration is advantageous for loading articles into packing cases or cartons that are partially compressed. For instance, in a compressed packing case or carton having openings arranged in rows, such as a six-pack beverage carrier that is not fully expanded and that has a central handle located between rows of openings, the drop zone for dropping articles into the case becomes smaller and narrower due to the adjacent rows of the case being pressed relatively close together. By utilizing finger guides configured in rows with vertical stationary finger guides in adjacent rows positioned adjacent to each other, the finger guides can conform to a compressed drop zone having openings arranged in rows. Thus, when the movable finger guides are in the closed position, the lower ends of the finger guides can be inserted into the upward facing openings of the compressed packing case or carton. When an article is dropped, the movable finger guide moves into the open position, thereby causing the opening in the packing case or carton to expand outward. As a charge of articles is dropped into each of the openings in the packing case, the entire case expands to its normal carrying size.

In another aspect, a grid unit is provided that can be installed on an existing drop packer. The unit is configured such that it can be operably connected to an existing drop packer. Once installed, the grid unit is configured to selectively release a charge of articles such that each article drops downward. The grid unit comprises a frame and a plurality of finger guides attached to the frame and extending downwardly from the frame. The finger guides are arranged in sets, wherein sets of finger guides are arranged in adjacent rows configured such that each article drops downward through a chute defined by a set of finger guides. Each set of finger guides comprises a stationary finger guide configured in a generally vertical position and a movable finger guide that can be moved into an open position to allow an article to drop through the chute or into a closed position. The movable finger guide is positioned at an acute angle to the stationary guide when in the closed position.

In another aspect, a method is provided for loading articles into a case packer utilizing a drop packer as disclosed herein.

The foregoing summary has outlined some features of the devices and methods of the present disclosure so that those skilled in the pertinent art may better understand the detailed description that follows. Additional features that form the subject of the claims will be described hereinafter. Those skilled in the pertinent art should appreciate that they can readily utilize these features for designing or modifying other structures for carrying out the same purposes of the devices and methods disclosed herein. Those skilled in the pertinent art should also realize that such equivalent designs or modifications do not depart from the scope of the devices and methods of the present disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:

FIG. 1 depicts a top perspective view of a partially compressed beverage carrier that may be utilized in accordance with the present disclosure.

FIG. 2A is a block diagram showing a standard drop zone for loading articles into packing cases using a drop packer.

FIG. 2B is a block diagram showing a compressed drop zone for loading articles into packing cases using a drop packer.

FIG. 3 shows a partial side elevational view of an apparatus for loading articles into packing cases in accordance with the present disclosure.

FIG. 4 shows a partial cross-sectional view of an apparatus for loading articles into packing cases in accordance with the present disclosure, as shown along line 4-4 therein.

FIG. 5 shows a partial side elevational view of an apparatus for loading articles into packing cases in accordance with the present disclosure.

FIG. 6 shows a partial cross-sectional view of an apparatus for loading articles into packing cases in accordance with the present disclosure, as shown along line 4-4 therein.

FIG. 7 shows a partial cross-sectional view of an apparatus for loading articles into packing cases in accordance with the present disclosure, as shown along line 7-7 therein.

FIG. 8 shows a partial cross-sectional view of an apparatus for loading articles into packing cases in accordance with the present disclosure, as shown along line 7-7 therein.

FIG. 9 shows a partial cross-sectional view of an apparatus for loading articles into packing cases in accordance with the present disclosure, as shown along line 7-7 therein.

FIG. 10 shows a partial cross-sectional view of an apparatus for loading articles into packing cases in accordance with the present disclosure, as shown along line 4-4 therein, with articles loaded into packing cases.

FIG. 11 shows a partial side elevational view of an apparatus for loading articles into packing cases in accordance with the present disclosure.

FIG. 12 shows a partial side elevational view of an apparatus for loading articles into packing cases in accordance with the present disclosure.

FIG. 13 shows a single finger guide that may be utilized with an apparatus for loading articles into packing cases in accordance with the present disclosure.

FIG. 14 shows a grid unit for a drop packer that may be utilized for loading articles into packing cases in accordance with the present disclosure.

DETAILED DESCRIPTION

Detailed descriptions of one or more preferred embodiments are provided herein. It is to be understood, however, that the present invention may be embodied in various forms. Therefore, specific details disclosed herein are not to be interpreted as limiting, but rather as a basis for the claims and as a representative basis for teaching one skilled in the art to employ the present invention in any appropriate manner.

Where reference is made herein to a method comprising two or more defined steps, the defined steps can be carried out in any order or simultaneously (except where the context excludes that possibility), and the method can include one or more other steps which are carried out before any of the defined steps, between two of the defined steps, or after all the defined steps (except where the context excludes that possibility).

The words “carton,” “cartons,” “case,” “cases,” “packing case,” and packing cases” may be used interchangeably and generally refer to a carton, case, or carrier for holding items.

In one aspect, a drop packer for loading articles into packing cases is provided. The drop packer may be used to load bottles, cans, or similar articles. The drop packer is configured such that it is capable of loading articles into packing cases that are partially compressed. As used herein “compressed” or “partially compressed” packing cases refer to any packing case that is not expanded to substantially its maximum size. FIG. 1 illustrates an example of one such packing case that me be utilized with the drop packer as disclosed herein. The packing case shown in FIG. 1 and a method of manufacturing the packing case are disclosed in U.S. Pat. No. 9,327,889, by the present Applicant. The entire contents of the foregoing patent are hereby incorporated herein by reference.

As shown in FIG. 1, the packing case 10 is a six-pack beverage carrier having two rows of individual sleeves 14 for holding beverage containers. The sleeves 14 are arranged in rows around a central handle 12 that extends upward from the top of each sleeve 14. The carrier shown in FIG. 1 is manufactured from a generally flat template that has portions which are folded and connected at opposite ends to form each of the sleeves 14 of the carrier 10. The creases seen in each of the sleeves 14 illustrate locations where the material may be folded. Because the material is folded during the manufacturing process, each sleeve 14 is typically not expanded to its maximum size when first manufactured and instead is in a partially flattened state. Thus, the carrier 10 is partially compressed when first manufactured, and the sleeves 14 must each be expanded to hold a beverage container. Before loading beverage containers, the sleeves 14 are positioned relatively closer to each side of the handle 12 than the sleeves 14 would be when holding a beverage container.

FIG. 2A shows a typical drop zone 20 for a drop packer being used to load charges of twenty-four articles into four fully expanded six-pack carriers. FIG. 2B shows a general representation of a narrower drop zone 22 for loading articles into compressed packing cases similar to the carrier 10 shown in FIG. 1. As seen in FIG. 2B, the openings for receiving articles are compressed and may not be large enough to receive articles therein without expanding the case beforehand. Packing cases providing a drop zone similar to the zone shown in FIG. 2B cannot be loaded using standard drop packers known in the art.

The carrier shown in FIG. 1 is an illustrative example of a compressed packing case that may be loaded using a drop packer as described in the present disclosure. During the manufacturing of this carrier 10, the sleeves 14 may be compressed to a greater or lesser degree than those shown in FIG. 1. In fact, each sleeve 14 may be compressed to a different degree than other sleeves during manufacturing due to variations in each of the sleeves and in the creasing in each sleeve. It should be understood by one skilled in the art that the drop packer disclosed herein may be used to load articles into compressed packing cases of various configurations, regardless of the degree of compression, as well as fully expanded packing cases.

As shown in FIG. 3, the drop packer utilizes a conveying system to convey packing cases 10 and articles 24 to be loaded, which, in this case, are bottles. An infeed conveyor 26 conveys the bottles 24 onto a grid unit 30 in a plurality of side-by-side lanes. The grid unit 30 is configured to selectively release a charge of articles 24 such that each of the articles drops downward through the grid unit 30.

FIG. 14 shows an illustrative grid unit 30 that may be utilized in accordance with the present disclosure. The grid unit 30 comprises a plurality of finger guides 50, 52 arranged in sets 48, wherein sets 48 of finger guides are arranged in adjacent rows. The rows of finger guides are configured such that each article 24 drops downward through a chute defined by a set 48 of finger guides. As best seen in FIG. 4, each set 48 of finger guides comprises a stationary finger guide 50 and a movable finger guide 52. The movable finger guide 52 can be moved into an open position to allow an article 24 to drop through the chute. The movable finger guide 52 can also be moved into a closed position. As seen in FIG. 4, which shows the movable finger guide 52 in the closed position, the stationary finger guide 50 is configured in a generally vertical position, and the movable finger guide 52 is positioned at an acute angle to the stationary guide 50 when in the closed position. In a preferred embodiment, the movable finger guide 52 is resiliently biased to the closed position.

As best seen in FIG. 5, the drop packer further comprises a lift platform 38 configured to lift one or more packing cases 10 upward such that the lower ends of the finger guides of each set 48 of guides are inserted into an upward facing opening in the one or more packing cases 10 when each movable finger guide 52 is in the closed position. After loading articles 24 into the packing cases 10, the lift platform 38 is returned to its lowered position and the loaded cases are conveyed downstream of the lift platform 38.

As best seen in FIGS. 4 and 6, each generally vertical stationary finger guide 50 is positioned adjacent to another generally vertical stationary finger guide 50 located in an adjacent row of finger guide sets 48. This configuration allows for each set 48 of guides to be inserted into corresponding rows of upward facing openings in a compressed packing case, such as the illustrative packing case 10 shown in FIG. 1. FIG. 7 shows the lower ends of finger guides 50, 52 inserted into upper openings in the packing cases 10. The generally vertical configuration of stationary guides 50 in adjacent rows allows the finger guides 50, 52 to clear the centrally located handle 12 of the case 10 and to be inserted into openings in the packing case 10 that are relatively close to the handle 12, as illustrated in FIG. 7. Thus, this configuration of finger guides 50, 52 allows the guides to be used for loading articles 24 into compacted drop zones.

To load articles 24 into packing cases 10 using a drop packer as disclosed herein, the infeed conveyor 26 conveys a charge of articles 24 onto the grid unit 30. In this particular embodiment, a charge of twenty-four bottles 24 is conveyed onto the grid unit 30 and loaded into four individual six-pack beverage carriers 10. Sets 48 of guide fingers are arranged in a 6-by-4 configuration, as seen in FIG. 14, and six-pack carriers 10 are arranged in a corresponding 2-by-2 configuration. FIG. 3 shows a side elevational view of this configuration, and FIG. 4 shows a sectional view as viewed along line 4-4 in FIG. 3. Of course, other configurations are possible and may be utilized with the apparatus and methods of the present disclosure.

A lower conveyor 40 conveys empty packing cases 10 to a position below the grid unit 30. With the movable finger guides 52 in the closed position, the lifting platform 38 is raised upward so that the lower ends of the finger guides 50, 52 of each set 48 of finger guides 50, 52 are inserted into an upward facing opening in a packing case 10, as shown in FIGS. 5 and 7. The charge of articles 24 is then released from the grid unit 30 so that the articles 24 drop downward through a chute defined by a set 48 of finger guides 50, 52 and into an upward facing opening in a packing case 10. When the articles 24 are dropped, the movable finger guide 52 of each set 48 of guides moves into the open position to allow each article 24 to drop into a packing case 10. When the movable finger guides 52 move into the open position, the motion of moving into the open position causes the openings in each packing case 10 to expand outward, thereby causing the entire case 10 to expand into its normal carrying size.

In a preferred embodiment, the movable finger guides 52 are resiliently biased to the closed position. The guides 52 may be resiliently biased utilizing springs, elastic connectors, or any similar means known in the art. As each of the articles 24 falls into each chute and contacts the inner portion of the finger guides, the weight of each article 24 forces the movable guide 52 into the open position, thereby expanding of the packing case 10. Once the articles 24 have been dropped into the packing cases 10, the lift platform 38 is lowered to its original position, and the movable finger guides 52 return to the closed position. FIGS. 8-10 illustrate this process. For example, FIG. 8 shows four separate bottles at various stages of being dropped into packing cases 10. As seen in this figure, the stationary guides 50 remain in the same generally vertical position, but the movable guides 52 move outward as each bottle passes between the guides 50, 52. The arrows shown on the beverage carriers in FIG. 8 indicate the outward expansion of the packing cases 10 as the bottles drop into the cases. Thus, the packing cases 10 expand due to both the outward motion of the movable guides 52 and the force of each bottle. FIG. 9 shows all of the finger guides 50, 52 in the open position after the bottles have been dropped into the cases. FIG. 10 shows the packing cases 10 loaded with bottles 24 after the lift platform 38 has been lowered and the finger guides 52 have returned to the closed position. The loaded packing cases 10 are then conveyed off of the lift platform 38 via the lower conveyor 40 and one or more empty cases are conveyed onto the lift platform 38 to repeat the loading process, as shown in FIG. 11.

In a preferred embodiment, the movable finger guides 52 are spring loaded such that a spring forces the movable guides 52 into the closed position. The springs are preferably configured such that the weight of a standard 12-ounce beverage bottle filled with a beverage is heavy enough to force the spring to compress by falling through the chute and contacting the inner portion of the finger guides. In an alternative embodiment, the motion of the movable guides 52 may be controlled by an actuator configured to open the movable guides 52 after the guides 50, 52 have been inserted into the upward facing openings of the packing cases and as the articles are dropped into the packing cases. The actuator will then move the guides 52 to the closed position after the packing cases have been lowered and before a new charge of articles are dropped.

Due to variations in different packing cases and articles being loaded into the cases, some articles may be packed unevenly. For instance, as shown in FIG. 12, the tops of bottles may not all be at the same height when loaded into beverage carriers such as the carrier shown in FIG. 1. To correct this potential problem, the drop packer may optionally further comprise a press 54 configured to selectively press downward on a group of articles 24 loaded into one or more packing cases 10. The press 54 is preferably controlled by a servo motor and is positioned above the lower conveyor 40 downstream from the grid unit 30 and lift platform 38. The press 54 is generally flat and configured in a generally horizontal position, as shown in FIG. 12. The bottom side of the press 54 preferably has padding to ensure that bottles or other fragile articles are not broken when pressed down upon. As shown in FIG. 12, the press 54 moves downward and presses the tops of each of the bottles or other articles that have been loaded into the packing cases to ensure even packing in the cases.

In another aspect, a grid unit 30 is provided that can be installed on an existing drop packer. The unit 30 is configured such that it can be operably connected to an existing drop packer. Once installed, the grid unit 30 is configured to selectively release a charge of articles such that each article drops downward. The articles are conveyed onto the grid unit 30 in side-by-side lanes define by lane guides 34. As shown in FIG. 14, the grid unit 30 comprises a frame 32 and a plurality of finger guides 50, 52 attached to the frame 32 and extending downwardly from the frame 32. The finger guides 50, 52 are arranged in sets 48, wherein sets 48 of finger guides are arranged in adjacent rows configured such that each article drops downward from the lanes and through a chute defined by a set 48 of finger guides. Each set of finger guides comprises a stationary finger guide 50 configured in a generally vertical position and a movable finger guide 52 that can be moved into an open position to allow an article to drop through the chute or into a closed position. The movable finger guide 52 is positioned at an acute angle to the stationary guide 50 when in the closed position. As shown in FIG. 14, the movable finger guides 52 can be seen on the exterior of the outside row of guide sets 48, while the generally vertical stationary finger guides are located on the interior side of the outside row of guide sets 48. FIG. 13 shows an illustrative example of a finger guide which may be used in the grid unit 30 assembly. It should be understood by one skilled in the art that finger guides in a variety of shapes, sizes, and materials of construction may be utilized in accordance with the proposed devices and methods and still fall within the scope of the present disclosure.

The grid unit 30 shown in FIG. 14 can retrofitted to existing drop packers with only minor modifications. The frame 32 may be modified to fit into existing drop packers and to be installed in existing drop packers. For instance, the Model 2800 Servo Case Packer manufactured by Hartness International, Inc., may be modified to incorporate the grid unit 30 described herein so that case packer can be used to load partially compressed packing cases. When modified, this case packer is effective in loading partially compressed six-pack carriers 32 having a central handle 2, such as the carrier 10 shown in FIG. 1, though it may be used to load any partially compressed packing case configured to hold rows of beverage containers or similar articles.

It is understood that versions of the invention may come in different forms and embodiments. Additionally, it is understood that one of skill in the art would appreciate these various forms and embodiments as falling within the scope of the invention as disclosed herein. 

What is claimed is:
 1. An apparatus for loading articles into packing cases, said apparatus comprising: an infeed conveyor configured to convey articles onto a grid unit in a plurality of side-by-side lanes, wherein the grid unit is configured to selectively release a charge of articles such that each article drops downward, wherein the grid unit comprises a plurality of finger guides arranged in sets, wherein sets of finger guides are arranged in adjacent rows configured such that each article drops downward through a chute defined by a set of finger guides, wherein each set of finger guides comprises a stationary finger guide configured in a generally vertical position and a movable finger guide that can be moved into an open position to allow an article to drop through the chute or into a closed position, wherein the movable finger guide is positioned at an acute angle to the stationary guide when in the closed position, and a lift platform configured to lift one or more packing cases upward such that the finger guides of each set of finger guides are inserted into an upward facing opening in the one or more packing cases when each movable finger guide is in the closed position.
 2. The apparatus of claim 1, wherein the movable finger guide of each set of finger guides is resiliently biased to the closed position.
 3. The apparatus of claim 1, wherein each stationary finger guide is positioned adjacent to a stationary finger guide located in an adjacent row of finger guide sets.
 4. The apparatus of claim 3, wherein the movable finger guide of each set of finger guides is resiliently biased to the closed position.
 5. The apparatus of claim 1, further comprising a press located downstream of the lift platform, wherein the press is configured to selectively press downward on a group of articles loaded into one or more packing cases.
 6. The apparatus of claim 5, wherein the movable finger guide of each set of finger guides is resiliently biased to the closed position.
 7. The apparatus of claim 5, wherein each stationary finger guide is positioned adjacent to a stationary finger guide located in an adjacent row of finger guide sets.
 8. The apparatus of claim 7, wherein the movable finger guide of each set of finger guides is resiliently biased to the closed position.
 9. A grid unit for a drop packer for loading articles into packing cases, wherein the grid unit is configured to selectively release a charge of articles such that each article drops downward, said grid unit comprising: a frame, and a plurality of finger guides attached to the frame and extending downwardly from the frame, wherein the finger guides are arranged in sets, wherein sets of finger guides are arranged in adjacent rows configured such that each article drops downward through a chute defined by a set of finger guides, wherein each set of finger guides comprises a stationary finger guide configured in a generally vertical position and a movable finger guide that can be moved into an open position to allow an article to drop through the chute or into a closed position, and wherein the movable finger guide is positioned at an acute angle to the stationary guide when in the closed position.
 10. The apparatus of claim 9, wherein the movable finger guide of each set of finger guides is resiliently biased to the closed position.
 11. The apparatus of claim 9, wherein each stationary finger guide is positioned adjacent to a stationary finger guide located in an adjacent row of finger guide sets.
 12. The apparatus of claim 11, wherein the movable finger guide of each set of finger guides is resiliently biased to the closed position.
 13. A method of loading articles into packing cases, said method comprising the steps of: providing one or more packing cases and a plurality of articles for loading into the one or more packing cases, providing an apparatus for loading the plurality of articles into the one or more packing cases, wherein the apparatus comprises: an infeed conveyor configured to convey articles onto a grid unit in a plurality of side-by-side lanes, wherein the grid unit is configured to selectively release a charge of articles such that each article drops downward, wherein the grid unit comprises a plurality of finger guides arranged in sets, wherein sets of finger guides are arranged in adjacent rows configured such that each article drops downward through a chute defined by a set of finger guides, wherein each set of finger guides comprises a stationary finger guide configured in a generally vertical position and a movable finger guide that can be moved into an open position to allow an article to drop through the chute or into a closed position, wherein the movable finger guide is positioned at an acute angle to the stationary guide when in the closed position, and a lift platform configured to lift one or more packing cases upward such that the finger guides of each set of finger guides are inserted into an upward facing opening in the one or more packing cases when each movable finger guide is in the closed position, conveying a charge of articles onto the grid unit, lifting one or more packing cases upward using the lift platform such that the finger guides of each set of finger guides are inserted into an upward facing opening in the one or more packing cases, and dropping the charge of articles downward such that each article drops through a chute defined by a set of finger guides and into an upward facing opening in a packing case, wherein the movable finger guide of each set of finger guides moves into an open position when an article drops downward to allow the article to drop into a packing case.
 14. The method of claim 13, wherein the one or more packing cases expand when the movable finger guide of each set of finger guides moves into the open position.
 15. The method of claim 13, wherein the movable finger guide of each set of finger guides is resiliently biased to the closed position.
 16. The method of claim 13, wherein each stationary finger guide is positioned adjacent to a stationary finger guide located in an adjacent row of finger guide sets.
 17. The method of claim 16, wherein the movable finger guide of each set of finger guides is resiliently biased to the closed position.
 18. The method of claim 13, further comprising the steps of: providing a press located downstream of the lift platform, wherein the press is configured to selectively press downward on a group of articles loaded into one or more packing cases, and employing the press to press downward on a group of articles.
 19. The method of claim 18, wherein the movable finger guide of each set of finger guides is resiliently biased to the closed position.
 20. The method of claim 18, wherein each stationary finger guide is positioned adjacent to a stationary finger guide located in an adjacent row of finger guide sets. 